Unclear charge conditions in the wet end can lead to quality losses, production disturbances, and higher additive consumption. Continuous monitoring is especially important when different chemicals are used to ensure process stability and specific quality requirements for base paper and finished products.
Reliable charge information helps optimise additive dosage throughout the wet-end process and gives mill personnel a clear overview of operating conditions.
As automation and digitalisation become increasingly important in the paper industry, automatic measurements providing accurate real-time process data are essential for meeting sustainability and resource-efficiency targets.
One such device is the emtec FPO Fiber Potential Analyzer Online, which automatically measures fibre zeta potential directly at the paper machine. It performs sampling, measurement and cleaning with very low maintenance requirements and can be connected at two points, allowing alternate sampling before and after additive dosing.
The FPO performs up to six measurements per hour, with four per hour as standard, depending on process requirements. Data include fibre zeta potential, conductivity, pH and temperature and are continuously transferred to the process control system, making changes in fibre charge immediately visible.
Online measurement eliminates the need for manual sampling and provides continuous real-time results, enabling immediate intervention in case of process instability or quality issues. Data can also be transferred to a secure cloud for remote access, allowing experts to support troubleshooting without being physically present on site.
In addition to measuring the charge of long- and short-fibre pulp and assessing charge conditions at the headbox, the FPO Fiber Potential Analyzer Online from EMTEC ELECTRONIC helps determine the optimal dosage of additives such as sizing agents, wet- and dry-strength agents, optical brighteners, softeners and dyes.
A practical example comes from a tissue mill producing different grades on an alternating basis, each with distinct specifications. Switching from toilet paper to kitchen towel requires changes in both pulp type and process chemicals. These adjustments alter the charge environment and especially the fibre surface charge, or zeta potential. Without this information, problems can arise in process runnability, final product quality and wastewater treatment.
The mill produces toilet paper, lower-quality kitchen towels, Type 1, and higher-quality kitchen towels, Type 2, using a dual headbox for short and long fibres. The emtec FPO was installed to monitor the zeta potential of both pulp grades after wet-strength agent, WSA, addition and before the dual headbox. Continuous monitoring stabilised runnability during frequent grade changes, improved wastewater treatment and reduced WSA consumption by 25%.
The online device does not replace laboratory trials and measurements, but the regular data supplied by the emtec FPO, combined with mill personnel experience, enables faster process optimisation and helps save resources, time and energy. It also supports workplace safety by reducing manual measurements while keeping the necessary data continuously available.
Automatic data transfer enables real-time risk monitoring, remote working and immediate access to test results from anywhere, facilitating collaboration between specialists and faster problem solving.
Remote access is particularly valuable for chemical suppliers, who can also use historical process data from continuous automated measurements. This allows faster responses to customer complaints and simplifies troubleshooting.
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